Fireplace surround

ABSTRACT

The invention generally relates to a fireplace surround for attachment to a fireplace. The surround may include first and second side members formed from a molded material, and a top member formed from the molded material that extends between the first and second side members. The top member defines a cavity that is in fluid communication with a vent of the fireplace to collect heated air from the fireplace. An opening formed in the top member facilitates movement of heated air collected in the cavity to pass through the cavity. The surround may also include a shield member that direct the heated air from the fireplace vent to the exhaust opening in the top member, and an insulating member that dissipates heat in the top member.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention generally relates to fireplaces, and moreparticularly relates to a fireplace surround for a fireplace.

2. Related Art

Fireplaces have become increasingly commonplace in homes, businesses,and other buildings. A fireplace provides benefits including thegeneration of heat as well as an aesthetically pleasing arrangement offlames, sounds, and smells. A fireplace is typically mounted in oradjacent to a wall and may include one or more exposed surfaces.

The fireplace box that defines the combustion chamber may assume anumber of different configurations. In traditional wood burningfireplaces of brick and mortar construction, the combustion chambergenerally extends over the full height of the. fireplace box, and alog-holding grate rests on the floor of the combustion chamber. For gasburning fireplaces, the burner assembly and associated gas supplymechanisms are typically located below the floor of the combustionchamber but often still within the open cavity defined by the fireplacebox. A number of fireplaces also include a heating plenum surroundingthe fireplace box. Typically, room air is drawn into the plenum near thebottom of the fireplace box, the air is heated as it travels around thefireplace box within the plenum, and the heated air is emitted back intothe room near the top of the fireplace box.

In order to provide an aesthetically pleasing design for the exposedfireplace front, most fireplaces include wide metal panels near the topand bottom portions of the open front fireplace box to cover or mask themechanisms and openings that are otherwise visible. Such panels may becoated with brass, bronze or anodized metal finishes for improvedaesthetics. The vertical area between the upper and lower decorativemetal panels generally contains one or more panels of glass that form aseal with the front of the fireplace box or include at least oneoperable door panel that provides access to the combustion chamber.

Metal panels typically used for fireplace surrounds conduct heat and maybecome unsafe to touch. Thus, it is desired to provide a fireplacesurround surface that has reduced heat conduction properties as comparedto a metal surface. Also, although the metal panels cover up unsightlyparts of the fireplace, the metal panels themselves may have pooraesthetics. Areas surrounding many fireplaces often include stone, brickor other natural materials or natural-appearing materials. For example,a hearth of the fireplace may be made of stone, brick, or the like.Therefore, the metal panel may contrast unattractively with the naturalmaterial surrounding the fireplace or the fireplace hearth. Moreover, itwould be expensive to create a top or bottom panel out of stone orbrick, and these materials generally prove difficult to shape and size.Also, the mounting of such material may be difficult due to the heavyweight of those materials.

Thus, it would be desirable from both aesthetic and cost viewpoints toprovide for a fireplace surround that improves the appearance of apre-existing or new fireplace while addressing at least thoseshortcomings of known fireplaces and fireplace surrounds noted above.

SUMMARY

The present invention generally relates to fireplaces and moreparticularly relates to fireplace surrounds. One aspect of the inventionrelates to a fireplace surround for attachment to a fireplace. Thesurround includes first and second side members formed from a moldedmaterial, and a top member formed from the molded material that extendsbetween the first and second side members. The top member defines acavity that is in fluid communication with a vent of the fireplace tocollect heated air from the fireplace. The top member also includes anopening that exhausts heated air from the cavity.

Another aspect of the invention relates to a fireplace that includes aheat source configured to generate heated air, a vent for exhausting theheated air outside the fireplace, and a fireplace surround. The surroundincludes first and second side members formed from a molded material,and a top member formed from the molded material that extends betweenthe first and second side members. The top member defines a cavity thatis in fluid communication with the heated air exhausted from the vent,and further defines an opening configured to exhaust the heated air fromthe cavity.

A yet further aspect of the invention relates to a fireplace surroundthat includes a molded first member having first and second sides and aninternal cavity defined by the first and second sides. The first side ofthe surround is open to provide a first access to the cavity, and thesecond side is defined by a sidewall that includes an aperture providinga second access to the cavity. The first side is configured for mountingto the fireplace adjacent a fireplace vent so that air heated by thefireplace passes through the first access into the cavity. The heatedair may then pass out from the cavity through the second access.

A further aspect of the invention relates to a method of forming afireplace surround for attachment to a fireplace. The method includesforming a first member from a molded material, wherein the first memberdefines a cavity and is configured for mounting to the fireplaceadjacent a vent of the fireplace. The method also includes forming anopening in the first member that provides access to the cavity so thatheated air from the fireplace may pass through the vent into the cavityand pass out from the cavity through the opening.

Yet another aspect of the invention relates to a fireplace ventingassembly that includes a return air plenum and a surround aligned withan opening of the plenum. The surround includes a surround opening thatextends through the surround to vent air from the plenum opening throughthe surround.

The above summary of the present invention is not intended to describeeach disclosed embodiment or every implementation of the presentinvention. Figures in the detailed description that follow moreparticularly exemplify embodiments of the invention. While certainembodiments will be illustrated and described, the invention is notlimited to use in such embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be more completely understood in consideration of thefollowing detailed description of various embodiments of the inventionin connection with the accompanying drawings, in which:

FIG. 1 is a perspective view of one example fireplace surround assemblyaccording to principles of the invention spaced apart from a fireplaceunit;

FIG. 2 is a cross-sectional side view of the surround assembly andfireplace unit shown in FIG. 1 taken along cross-sectional indicators2-2;

FIG. 3 is a front view of the fireplace surround assembly shown in FIG.1;

FIG. 4 is an exploded perspective view of the fireplace surroundassembly shown in FIG. 1;

FIG. 5 is a close up view of the cross-sectional view of the surroundtop member shown in FIG. 2;

FIG. 6 is a rear view of the fireplace surround assembly shown in FIG.1;

FIG. 7 is a top view of the fireplace surround assembly shown in FIG. 1;

FIG. 8 is a side view of the fireplace surround assembly shown in FIG.1;

FIG. 9 is an exploded rear perspective view of an access panel that maybe added to the fireplace surround assembly shown in FIG. 1;

FIG. 10 is a front view of the access panel shown in FIG. 9; and

FIG. 11 is a front view of the fireplace surround assembly of FIG. 1including the access panel shown in FIG. 9.

While the invention is amenable to various modifications and alternantforms, specifics thereof have been shown by way of example and thedrawings and will be described in detail. It should be understood,however, that the intention is not to limit the invention to theparticular embodiments described. On the contrary, the intention is tocover all modifications, equivalents, and alternatives falling withinthe spirit and scope of the invention.

DETAILED DESCRIPTION

The present invention generally relates to fireplaces and moreparticularly relates to fireplace surrounds. In many fireplaceapplications, it is desirable to cover the metal top, bottom and sidepanels of a fireplace, the gap that typically exists between thefireplace and the finished wall surface around the fireplace, and thevents and access openings and controls of the fireplace. In manyapplications, a fireplace surround or surround assembly as well as afireplace front must be used to provide the desired aesthetic affect.Further, it may be desirable to use covering materials for the surroundthat have a natural appearance that blends with the fireplace hearth andother features around the fireplace, and to use covering materials thatare low-cost and relatively easy to form into desired shapes. Moreover,it is often desirable for a fireplace surround to have low heatconductive properties to improve safety of the fireplace. The followingexample fireplace surrounds address these and other objectives andprovide an improvement over known fireplace surrounds. While the presentinvention is not so limited, an appreciation of the various aspects ofthe invention will be gained through a discussion of the examplesprovided below.

As used herein, the term “surround” means any exposed structural surfacethat covers at least a portion of the front surface of a fireplace andprovides a transition from the combustible material surrounding thefireplace (such as, for example, a sheetrock wall) to the sheet metal ofthe fireplace front. The “surround” may function as a door or similarstructure that provides access to otherwise covered features of thefireplace. The “surround” may also function as a fireplace front thatcovers portions of the fireplace, for example, the fireplace viewingsurface (e.g., glass), frame or louvers. Thus, a surround according toprinciples of the invention may be advantageous for combining severalfunctions of previously required pieces (i.e., door, surround, andfront) into a single unit, thereby saving cost for the consumer whileproviding an aesthetically pleasing solution.

The phrase “viewing surface” is any surface through which at least aportion of an interior of a fireplace may be viewed. For example, aviewing surface may consist of a pane of translucent tempered or ceramicglass or high-temperature plastic positioned to cover at least a portionof an opening of a fireplace. The phrase “combustion chamber enclosure”may include any enclosure in which flames and/or heat are generated orsimulated. The term “fastener” includes, for example, magnets, clamps,brackets, bolts, screws, and similar structures that secure together twoor more members.

An example fireplace 50 illustrated in FIGS. 1 and 2 includes an outerenclosure 60, a viewing surface 70, upper and lower grills 80, 90, upperand lower vents 85, 95, a combustion chamber enclosure 62, and acombustion chamber 64. A burner 66 positioned in the combustion chamberenclosure combusts gas and thereby generates heat. The burner istypically coupled by a gas line to a source of combustible gas. Thesefeatures are standard on gas fireplaces and, therefore, are notidentified in the drawings. A suitable example fireplace for use with asurround disclosed herein is described and illustrated in U.S. PatentApplication Publication No. 2003/0089365, which is incorporated hereinby reference in its entirety.

Fireplace 50 may be any type of fireplace, such as, for example, asolid-fuel, gas, or electric fireplace. In the example embodiment, thefireplace 50 is a gas fireplace. Fireplace 50 is provided as an exampleonly, and any other known configuration for a fireplace may also beused. For example, the present invention may be used in conjunction withany prefabricated gas fireplace such as, for example, a direct vent, auniversal vent, a B-vent, a horizontal/vertical-vent, a dual directvent, or any fireplace unit to which the present fireplace surround maybe fitted. Further, the invention may be utilized in any configurationof a solid-fuel burning or electric fireplace as well.

Lower vent 85 acts as a room air intake that draws relatively cool roomair (in the direction A) into a plenum 75 (portions of which are shownin FIG. 2) that surrounds the combustion chamber enclosure 62 andprovides fluid communication between the top and bottom vents 85, 95. Asthe cool air drawn in through lower vent 85 moves around the combustionchamber enclosure 62, heat emanating from combustion chamber 64 heatsthe air. The heated air rises naturally in the plenum, or is movedthrough the plenum with a blower (not shown), towards upper vent 85. Theheated air then exits upper vent 85 (in the direction B), which ventserves as an exhaust for the heated air.

A fireplace surround assembly 100 shown in FIGS. 1-8 may be mounted orpositioned adjacent to outer enclosure 60 of fireplace 50. Surroundassembly 100 includes a top member 102 that extends in a generallyhorizontal direction between two vertically oriented side members 104,106. In addition, surround assembly 100 includes a lower horizontalmember 108, although this feature may not be included in someembodiments. Side members 104, 106 and top and lower members 102, 108may be integrally formed together as a single piece or may be formed asseparate pieces or groups of pieces that are then assembled togetherusing, for example, fasteners, adhesives, or some other assembly means.The horizontal direction referred to herein is with respect to ahorizontal plane, such as a plane associated with a floor surface onwhich the surround and fireplace rest, and a vertical plane isorientated in a direction perpendicular to the horizontal plane.

Surround assembly 100 may be constructed of molded materials, forexample, a molded material that includes an inorganic ceramic fiber anda binder. The molded materials may be formed by any known moldingtechnique, such as, for example, compression molding or vacuum formingtechniques. Exemplary compression molding compositions and formingtechniques are described in pending United States Patent ApplicationPublication No. 2003/0049575, which is incorporated herein by referencein its entirety. Additional exemplary molding compositions and formingtechniques are described in U.S. Pat. Nos. 5,941,237; 5,996,575; and6,170,481, which are also incorporated herein by reference in theirentirety.

The use of molded materials provides potential design and functionaladvantages for a surround. For example, the various brackets describedherein may be directly molded into the surround rather than beingseparately secured to the surround with a fastener or the likeattachment means. Further options may include directly molding wiring,switches, lighting, and various control features into the molded portionof the surround.

The exact shaping of the fireplace surround 100 may be entirely formedduring the compression or vacuum molding process or it may be formedthrough post-article forming manufacturing processes, such as, forexample, drilling, etching, sawing, milling, or other processes. Thecompression or vacuum molded materials may be formed and colored so asto have the appearance of stone, brick, or any other natural materialthat may be desired. Molding processes may be particularly useful forcreating surrounds with complicated features that would otherwise bedifficult to create if using other methods, such as stamping. Forexample, a top member formed using a molding process may include acontoured exterior surface, an inner cavity with planar or contouredsurfaces, and an aperture formed between the exterior surface andcavity, which features may all be formed in a single step of forming thetop member.

Top member 102 may include front and rear facing sides 111, 113, whereinfront facing side 111 is defined by a sidewall 115 that defines a cavity105, and rear facing side 113 is open. In other embodiments, rear facingside 113 may be partially closed with a sidewall and include aperturesaligned with vent 95 to permit the flow of air into cavity 105.

Top member 102 may include one or more apertures 103 formed in sidewall115 that provide fluid communication between cavity 105 and air on theoutside of sidewall 115. The number and orientation of apertures 103 maydepend on the configuration of grill 90 and vents 95. The generallydownward facing orientation of apertures 103 shown in FIG. 4 may bedesired for directing heat into a room area at a downward angle,although other embodiments may include additional or replacementapertures oriented in different directions.

Surround assembly 100 may also include a shield member 130 and aninsulating member 160 that are mounted to top member 102 within cavity105, as shown in FIGS. 4-6. Brackets 110, 120 may be used to secureinsulating and shield members 160, 130 to top member 102 (see FIG. 6).As shown in FIGS. 7 and 8, the shield and insulating members 130, 160are mounted within top member 102 (see side and top profiles of assembly100 shown in FIGS. 7 and 8) that top member 102 can be flush mountedagainst outer enclosure 60 of fireplace 50.

When surround assembly 100 is mounted or positioned adjacent to outerenclosure 60 of fireplace 50, rear facing side 113 is aligned with vent95 so that heated air exhausted from vent 95 passes into cavity 105.Shield member 130 is positioned relative to vent 85 so that the air fromvent 95 is directed at an angle toward aperture 107 along a pathrepresented by arrows 109. Because the air being exhausted through vent95 is typically heated, contact by this air against shield member 130may cause the shield member to become very hot. In other embodimentsthat do not include a shield member, the heated air may contact sidewall115 resulting in the entire surround to become very hot. In order toprevent sidewall 115 from becoming heated to the point that it may be asafety hazard, insulating member 160 is positioned so as to be betweenvent 95 and sidewall 115 to absorb and dissipate heat. In the embodimentillustrated in FIGS. 4 and 6, insulating member 160 is positionedbetween shield member 130 and sidewall 115.

Surround assembly 100 preferably rests flat on a floor surface in frontof the fireplace 50. In this manner the floor primarily supports theweight of surround assembly 100. Alternatively, the surround 100 may beattached to fireplace 50 without being supported by the floor.

Surround assembly 100 may be attached to the existing fireplace 50 byleft and right side pawl assemblies (connectors) 140, 150. Each pawlassembly 140, 150 is connected to the back of the surround assembly 100(see FIG. 6), and may be adjusted into a surface of fireplace 50.Alternatively, surround assembly 100 may be connected to fireplace 50 byany appropriate mechanical means, such as using bolts, screws, adhesive,or the like securing methods. Surround assembly 100 may, in someembodiments, be a freestanding unit that is placed in front of fireplace50 without any means of connection to fireplace 50.

As shown in the figures, the edges of surround assembly 100 arecontoured to improve aesthetics and to remove any sharp edges that couldcause injury. However, other shapes or configurations, such as arectangular shape or any other multi-faceted shape, are contemplated bythe present invention.

Surround assembly 100 may further include an access panel 170 thatextends along a bottom portion of fireplace 50, for example, betweenfirst and second side members 104, 106 below lower member 108. Accesspanel 170 may be attached to first and second side members 104, 106 withbrackets 172, 174. Brackets 174 may be magnets, snap-fit structures, orother quick release fastening structures that may be secured to brackets172 (such as with a fastener 176). The quick release nature of accesspanel 170 may provide easy access to certain features of fireplace 50,such as controls for a gas burner, a blower or other mechanisms of thefireplace. If no access to fireplace 50 is needed or desired, or if theneed for access is limited, access panel 170 may be permanently attachedto surround 100 by screws or the like.

Access panel 170 may be positioned so as to provide a gap (see FIG. 11)between the lower horizontal member 108 and the access panel 170 toallow intake air to flow freely into vent 85 of fireplace 50. However,this gap does not have to be present nor does the gap have to be aslarge as shown in FIG. 11. Alternatively, the gap may also be positionedbelow access panel 170.

In the examples described above, the exhaust vent 95 is positioned at anupper portion of fireplace 50, which position may be advantageous forsome fireplace designs. However, in other embodiments, the exhaust ventsmay be located at other locations around the fireplace, such as alongvertical sides or across the bottom of the fireplace. In suchalternative embodiments, a portion of the surround assembly equivalentto top member 102 that includes, for example, a cavity, apertures,shields and insulation may be aligned with the fireplace exhaust vent soas to provide the advantages and functions of the examples describedabove.

In another aspect of the invention, a surround is provided for use witha return air plenum, for example the fireplace plenum discussed above.The surround includes an opening that extends through the surround sothat air exhausted from an opening of the plenum vents through thesurround opening.

The present invention should not be considered limited to the particularexamples or materials described above, but rather should be understoodto cover all aspect of the invention as fairly set out in the attachedclaims. Various modifications, equivalent processes, as well as numerousstructures to which the present invention may be applicable will bereadily apparent to those of skill in the art to which the presentinvention is directed upon review of the instant specification.

1. A surround for attachment to a fireplace, comprising: first andsecond side members formed from a molded material; a top member formedfrom the molded material and extending between the first and second sidemembers, the top member defining a cavity that is in fluid communicationwith a vent of the fireplace to collect heated air from the fireplace;and an opening defined by the top member, the opening configured toexhaust the collected air from the cavity.
 2. The surround of claim 1,wherein the first and second side members extend in a substantiallyvertical direction.
 3. The surround of claim 1, wherein the top memberextends in a substantially horizontal direction.
 4. The surround ofclaim 1, further comprising a lower member extending between the firstand second side members at a position vertically below the top member.5. The surround of claim 4, wherein the first and second side membersand the top member are constructed as a single, monolithic piece.
 6. Thesurround of claim 5, further comprising an access panel secured to thesurround at a position vertically below the lower member.
 7. Thesurround of claim 6, wherein the access panel is removably secured tothe surround by at least one fastener.
 8. The surround of claim 1,wherein the opening defined by the top member includes at least twodistinct openings.
 9. The surround of claim 1, further comprising aninsulating member configured to fit within a portion of the cavity. 10.The surround of claim 1, further comprising a connector configured tosecure the surround to the fireplace.
 11. The surround of claim 1,wherein the molded material includes a ceramic fiber and a binder.
 12. Afireplace, comprising: a heat source configured to generate heated air;a vent for exhausting the heated air outside the fireplace; and afireplace surround, the surround including: first and second sidemembers formed from a molded material; a top member formed from themolded material and extending between the first and second side members,the top member defining a cavity that is in fluid communication with theheated air exhausted from the vent; and an opening defined by the topmember, the opening configured to exhaust the heated air from thecavity.
 13. The surround of claim 12, further comprising an insulatingmember configured to fit within a portion of the cavity.
 14. Thesurround of claim 12, further comprising a shield member configured todirect heated air exhausted from the vent through the cavity.
 15. Thesurround of claim 14, wherein the top member is positioned verticallyabove the combustion chamber.
 16. The surround of claim 1, wherein themolded material includes a ceramic fiber and a binder.
 17. A fireplacesurround, comprising: a molded first member having first and secondsides and an opening extending between the first and second sides;wherein the first side is configured to be positioned adjacent to a ventof the fireplace so that heated air exhausted from the fireplace ventmoves through the opening.
 18. The surround of claim 17, furthercomprising an insulating member positioned in the first member.
 19. Thesurround of claim 17, wherein the first member is molded from a materialthat includes a ceramic fiber and a binder.
 20. The surround of claim17, further comprising a cavity formed in the first member between thefirst and second sides, and the opening provides access to the cavity.21. The surround of claim 17, further comprising a shield memberconfigured to direct air through the opening.
 22. A method of forming afireplace surround for attachment to a fireplace, the method comprisingthe steps of: forming a first member from a molded material, the firstmember being configured for positioning adjacent to a vent of thefireplace; and forming an opening in the first member that extendthrough the first member; wherein heated air exhausted from thefireplace vent moves through the opening in the first member.
 23. Themethod of claim 22, further comprising the step of forming a cavitywithin the first member, wherein the opening provides access to thecavity.
 24. The method of claim 22, further comprising the step offorming first and second side members from the molded material andorienting the first and second side members along vertical sides of thefireplace.
 25. The method of claim 22, further comprising the step offorming a lower member and orienting the lower member horizontallyacross a lower portion of the fireplace.
 26. The method of claim 22,further comprising the step of orienting the first member horizontallyacross an upper portion of the fireplace.
 27. The method of claim 25,further comprising the step of forming an access panel configured forattachment to the surround at a location below the lower member.
 28. Themethod of claim 27, further comprising the step of releasably securingthe access panel to the surround with a fastener.
 29. The method ofclaim 22, wherein the step of forming an opening includes forming atleast two openings in the first member that each extend through thefirst member.
 30. The method of claim 23, wherein the surround furthercomprises an insulating member and the method further comprises the stepof positioning the insulation member in the cavity.
 31. The surround ofclaim 22, wherein the step of forming the first member includescompression molding the first member from a molded material thatincludes a ceramic fiber and a binder.
 32. The surround of claim 22,wherein the step of forming the first member includes vacuum molding thefirst member from a molded material that includes a ceramic fiber and abinder.
 33. A fireplace venting assembly, comprising: a return airplenum; and a surround aligned with an opening of the plenum andincluding a surround opening that extends through the surround to ventair from the plenum opening through the surround.